Grid form panel masonry veneer from liner

ABSTRACT

The present invention is a masonry veneer holding form liner, primarily in pattern shapes of mortar joints surrounding an assembly of placed masonry veneers, usually attach by screws or bolts, to the exterior face of a concrete/cementitious grid flow-through forming panel. Masonry veneers are placed into the masonry veneer holding form liner spaces. When concrete/cementitious material is poured into a vertical or horizontal oriented forming cavity the concrete/cementitious material flows through the grid openings of the grid forming panel&#39;s grid openings up to the interior face of the masonry veneer and up to the interior side of the masonry veneer holding form liner. After the concrete/cementitious material hardens the mortar joint pattern holding form liner is released from the exterior of the grid form, exposing the face of the masonry veneer and the concrete/cementitious poured material now representing the mortar joint between the masonry veneers.

CROSS REFERENCE TO RELATED APPLICATION

Reference is made to the Applicants patent, McCary, U.S. 2010/0051779, now U.S. Pat. No. 8,153,046, and incorporates by reference the disclosure of the earlier application and then patent to the extent necessary for a full enabling disclosure of the present invention.

FIELD OF THE INVENTION

This invention relates to the masonry veneer form liner used with a concrete/cementitious material flow-through grid forming panel during a concrete/cementitious pour.

BACKGROUND OF THE INVENTION

Conventional, concrete forms consist of plywood or wooded and metal panels temporarily maintained in spaced apart and parallel relationship by means of ties. The concrete in poured between these forms which are then stripped away after the concrete has set up. These panels can be expensive and awkward to manufacture, store, and ship.

Alternatively and more recently forms such as insulated concrete forms with foamed plastic panel that becomes part of the poured wall or structure have gained acceptance in the construction industry. Some difficulties have developed in some applications due to the outside of the panel being made of foam plastic which include; penetrability of the foamed plastic, insect entrance questions, waterproofing difficulties, the stigma of previous stucco (EIFS) application failures and the question of fire ratings.

In McCary, U. S. 2010/0051779, now U.S. Pat. No. 8,153,046, discloses a method of assembling a plurality of modular forming units to create a freestanding structure, wherein each unit consists of a least one lattice or grid framework panel having a plurality of openings there through and another spaced apart forming panel to create a forming cavity.

Concrete/cementitious flowable material is introduced into the cavity, wherein the concrete/cementitious flowable material fills the cavity and flows non-restrictively through the lattice framework panel(s) such that the cementitious material extends beyond the external surface of the lattice framework or grid panel(s) creating an external surface layer; and then allowing the material to set and become a monolithic structure. McCary had described the attachment of stencils and form liners to the exterior face of the concrete/cementitious grid flow-through forming panel but had not addresses the attaching of masonry veneers, such as thin brick, to the exterior face of the grid form panel before the concrete/cementitious pouring into the cavity of the concrete/cementitious form.

Various patents were issued to masonry veneer style holding forms, including Goldman, U.S. Pat. No. 4,858,410 Aug. 22, 1989, where masonry veneer could be placed in horizontally placed holding forms with the face or to be exposed side of the masonry veneer facing down. Then concrete/cementitious material would be poured upon the masonry veneer and holding form. When the concrete/cementitious material had dried sufficiently then the masonry veneer holding form would be pulled off exposing the face of the masonry veneer and the concrete/cementitious poured material now representing the mortar joint between the masonry veneers.

Vertical applications were introduced of holding masonry veneers in a vertical holding form or bracket, as in Scott, U.S. Pat. No. 5,667,190 Sep. 16, 1997, later in Scott, U.S. Design Pat. No. D625,846 Oct. 19, 2010, in Marshall, U.S. Pat. No. 6,360,505 and in Williams, U.S. Pat. No. 6,360,505, Mar. 26, 2002. In Scott, Marshal and Williams, masonry veneers holding forms are attached on the interior face of a vertical concrete/cementitious forming panels and masonry veneers placed in the masonry veneer holding forms before the concrete/cementitious pour into the forming cavity. After the concrete/cementitious material is poured and allowed to harden to the desired stiffness the forming panels are removed along with the masonry veneer holding forms, exposing the face of the masonry veneer and the concrete/cementitious poured material now representing the mortar joint between the masonry veneers.

THE INVENTION

The present invention is a masonry veneer holding form liner that attaches to the exterior face of a concrete/cementitious grid flow-through forming panel. The grid form masonry veneer holding form liner is primarily in pattern shapes of the mortar joints surrounding an assembly of masonry veneers such as bricks, thin bricks, stone, thin stone, block or thin block. There are periodically spaced holding or catch points on the circumference of the mortar joint pattern. The masonry veneer holding form liner is attached to the concrete/cementitious flow-through grid form usually by screws and bolts that protrude through periodic holes in the grid form mortar shaped masonry veneer holding form liner. The attaching screws or bolts either then have grapple style catches then attached to the attaching ends of the screws or bolts or the screws or bolts without grapple catch first attached are pushed through the concrete/cementitious grid form grid openings and then a grapple style catch, wing nut style catch or other catch that holds the mortar joint patterned masonry veneer holding form liner on the exterior face of the concrete/cementitious flow-through grid forming panel. Masonry veneers, usually thin bricks, thin blocks, tiles or pavers can then be placed into the masonry veneer holding form liner spaces between the mortar joint pattern masonry veneers holding form liner. Either periodically placed catches on the circumference of the holding form liner masonry veneer holding spaces or friction of the mortar joint pattern holding form hold the placed masonry veneers in place during a concrete/cementitious pour. When concrete/cementitious material is poured into the vertical or horizontal (as in pavers, tiles) oriented forming cavity with the masonry holding form liner attached to the concrete/cementitious flow-through grid forming panel(s) the concrete/cementitious material flows through the grid openings of the grid forming panel's grid openings up to the interior or non-exposed face of the masonry veneer and up to the interior side of the masonry veneer holding form liner. After the concrete/cementitious material is allowed to harden to the desired stiffness the masonry veneer holding forms are unscrewed or unbolted from the concrete/cementitious embedded grapple, wing nut or other style holding catch and masonry veneer mortar joint pattern holding form liner is released from the exterior of the grid form, exposing the face of the masonry veneer and the concrete/cementitious poured material now representing the mortar joint between the masonry veneers. Alternatively, the concrete/cementitious poured material now representing the mortar joint between the masonry veneer can be so narrow that all or a portion of the masonry veneers have the appearance of dry stacked, having no mortar joint, or very narrow mortar joint.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1. in a frontal view shows a mortar joint patterned masonry veneer holding form liner with a masonry veneer placed in one of the masonry veneer placement and holding openings.

Shown in FIG. 2., in a side cross-sectional view, a mortar joint patterned masonry veneer holding form liner attached to a concrete/cementitious flow-through grid forming panel.

FIG. 3., in a side cross-sectional view shows a mortar joint patterned masonry veneer holding form liner attached to a concrete/cementitious flow-through grid forming panel with masonry veneers placed in the mortar joint patterned masonry veneer holding form liner.

Shown in FIG. 4., in a side cross-sectional view, is concrete/cementitious material poured into a vertical or horizontal oriented concrete/cementitious form with one of the forming panels being a concrete/cementitious flow-through grid forming panel with an attached mortar joint patterned masonry veneer holding form liner with masonry veneer placed in the mortar joint patterned masonry veneer holding form liner.

FIG. 5. shows in a side cross-sectional view the hardened concrete/cementitious material that was poured into a concrete/cementitious form with one of the forming panels being a concrete/cementitious flow-through grid forming panel with a previously attached mortar joint patterned masonry veneer holding form liner removed now showing the exposed face of the masonry veneer and the concrete/cementitious mortar joints.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1. in a frontal view shows the mortar joint patterned masonry veneer holding form liner 10 with the mortar joint patterned form liner 11, the masonry veneer placement and holding openings 12, with a masonry veneer 13 placed in one of the masonry veneer placement and holding openings 12. Shown are circumference catch points 14 that help to hold the placed masonry veneer 13 on the circumference of the mortar joint patterned form liner 11. Also shown are attaching holes 15 periodically placed in the joint patterned form liner.

Shown in FIG. 2., in a side cross-sectional view, a mortar joint patterned masonry veneer holding form liner 10 attached to a concrete/cementitious flow-through grid forming panel 16. Shown are attaching screws, bolts or other threaded rod style fasteners 17 placed through holes 15 in the joint patterned form liner 10, pushed through the grid openings 18 of the concrete/cementitious material flow-through grid form 16, with a grapple catch, wing nut or other threaded holding catches 19 attached to the attaching ends 20 of the screws, bolts or other threaded rod style fastener 17. The side of circumference catch points 14 and offset screed points 21 on the side of the concrete/cementitious flow-through grid forming panel 16 are also shown.

FIG. 3., in a side cross-sectional view shows a mortar joint patterned masonry veneer holding form liner 10 attached to a concrete/cementitious flow-through grid forming panel 16 with masonry veneers 13 placed in the veneer placement and holding openings 12 of the mortar joint patterned masonry veneer holding form liner 10, with the placed masonry veneers 13 resting close to or against the offset screed points 21. Shown are the circumference catch points 14 helping to hold the masonry veneers 13. Again shown are attaching screws, bolts or other threaded rod style fasteners 17 placed through holes 15 in the mortar joint patterned from liner 10, pushed through the grid openings 18 of the concrete/cementitious material flow-through grid form 16, with a grapple catch, wing nut or other threaded hold catches 19 attached to the attaching ends 20 of the screws, bolts or other threaded rod style fastener 17.

Shown in FIG. 4., in a side cross-sectional view, is concrete/cementitious material 22 poured into a vertical or horizontal oriented concrete/cementitious form 23 with one of the forming panels being a concrete/cementitious flow-through grid forming panel 16 with an attached mortar joint patterned masonry veneer holding form liner 10, with masonry veneer 13 placed in the mortar joint patterned masonry veneer holding form liner 10. Shown are the circumference catch points 14 and the offset screed points 21. The other forming panel of the concrete/cementitious form 23 is a solid vertical or horizontal oriented forming panel 24. Shown are attaching screws, bolts or other threaded rod style fasteners 17 placed through holes 15 in the mortar joint patterned from liner 10, pushed through the grid openings 18 of the concrete/cementitious material flow-through grid form 16, with a grapple catch, wing nut or other threaded holding catch 19 attached to the attaching ends 20 of the screws, bolts or other threaded rod style fastener 17. The concrete/cementitious material 22 is shown flowing through 25 the grid openings 18 of the concrete/cementitious material flow-through grid form panel 16 up to and adhering to the interior or non-exposed face 26 of the masonry veneer 13, and the concrete/cementitious material 22 is shown flowing up to the interior side 27 of the mortar joint patterned masonry veneer holding form liner 10.

FIG. 5. shows in a side cross-sectional view the hardened concrete/cementitious material 22 that was poured into a concrete/cementitious form 23 with one of the forming panels being a solid panel 24 and the other forming panel is a concrete/cementitious flow-through grid forming panel 16 with attached offset screed points 21. A previously attached mortar joint patterned masonry veneer holding form liner 10 is shown removed, now showing the exposed face 28 of the masonry veneer 13 and the hardened concrete/cementitious material 22 as mortar joints 29 between the masonry veneers 13. 

1. A concrete/cementitious material flow-through grid form masonry veneer holding form liner, comprising: a. concrete/cementitious material flow-through grid form, wherein there is a concrete/cementitious vertically or horizontally oriented concrete/cementitious form where the forms consists of a least one lattice or grid framework panel having a plurality of openings there through and another spaced apart vertical or horizontally oriented forming panel to create a forming cavity where concrete/cementitious flowable material is introduced into the cavity, wherein the concrete/cementitious flowable material fills the cavity and flows non-restrictively through the lattice framework panel(s) such that the cementitious material extends beyond the external surface of the lattice framework or grid panel(s) creating an external surface layer; and then allowing the material to set and become a monolithic structure; and b. masonry veneer, wherein a vertical or horizontal surface can have adhered protective and decorative masonry products, including brick, thin brick, block, thin block stone, thin stone, concrete/cementitious manufactured stone, tiles and pavers; and c. mortar joint pattered masonry veneer holding form liner, wherein a masonry veneer holding form liner is in the primary patterned shape of mortar joints surrounding masonry veneers, said masonry veneer holding form liner would have openings for the placement and holding of masonry veneers; and d. circumference catches, wherein there are periodically placed catches on the circumference of the mortar joint pattered masonry veneer holding form liner masonry veneer placement and holding openings; and e. grapple style catches, wherein there are grapple shaped style catches that can be attached to the attaching ends of screws, bolts or other threaded fasteners that can be pushed through the grid openings of a concrete/cementitious material flow-through grid form; and f. the mortar joint patterned masonry veneer holding form liner has periodically placed holes that screws, bolts or other threaded rod style fasteners can be placed through; and g. a grapple style catches can then be attached to the attaching ends of the screws, bolts or other treaded rod style fasteners are pushed through the grid openings of the concrete/cementitious material flow-through grid form; or h. alternatively the screws, bolts or other treaded rod style fastener without an attached grapple style catch can be first pushed through the grid openings of the concrete/cementitious material flow-through grid form; and i. a grapple style catch, wing nut or other threaded style holding catches can then be attached to the attaching ends of the screws, bolts or other threaded rod style fastener, with the grapple catch, wing nut or other threaded style holding catch holding the mortar joint patterned masonry veneer holding form liner to the exterior face of the concrete/cementitious material flow-through grid form; and j. masonry veneer is then placed into the masonry veneer placement and holding openings of the mortar joint pattered masonry veneer holding form liner; and k. circumference catches, or the friction of the mortar joint patterned masonry veneer holding form liner against the masonry veneers, hold the masonry veneers in place; and l. when concrete/cementitious material is poured into the cavity of the concrete/cementitious form with a concrete/cementitious material flow-through grid form masonry veneer holding form liner being one or both of the concrete/cementitious forming panels the concrete/cementitious material flows through the grid openings of the grid forming panel's grid openings up to and adhering to the interior or non-exposed face of the masonry veneer, and the concrete/cementitious material flowing up to the interior side of the mortar joint patterned masonry veneer holding form liner; and m. after the poured concrete/cementitious material is allowed to harden to the desired stiffness the screws, bolts or other threaded rod style fasteners are unscrewed, unbolted or unfastened from the concrete/cementitious embedded grapple style catch, wing nut or other threaded style holding catch; and n. the mortar joint patterned masonry veneer holding form liners are released from the face of the masonry veneer and the poured concrete/cementitious material; and o. the face of the masonry veneer is exposed with the now hardened concrete/cementitious poured material now visually representing the mortar joints between the masonry veneers.
 2. A concrete/cementitious material flow-through grid form masonry veneer holding form liner of claim 1, wherein after the poured concrete/cementitious poured material has flowed up to the interior side of the mortar joint patterned masonry veneer holding form liner, the concrete/cementitious material has hardened and the form masonry veneer holding form liner now removed said concrete/cementitious material representing the mortar joint between the masonry veneers can be so narrow that all or a portion of the masonry veneers have the appearance of dry stacked, having no mortar joint, or very narrow mortar joint.
 3. A concrete/cementitious material flow-through grid form masonry veneer holding form liner of claim 1, wherein when pouring a horizontal oriented concrete/cementitious cavity surface, screws, bolts or other threaded rod style fasteners attached to grapple catches, wing nuts or other threaded style holding catches may not be required to hold the mortar joint patterned masonry veneer holding form liner attached to the concrete/cementitious material flow-through grid form. 